ASTEC 40 Series User manual

IB-2003 8/14
Model 5044-32T
Sand Prep
Material
Handling
OPERATION AND MAINTENANCE MANUAL
Series 40 Tranflite - Stationary Conveyor
Series 40 Conveyor

CALIFORNIA
Proposition 65 Warning
Dieselengineexhaustandsomeofitsconstituentsareknowntothestate
ofCaliforniatocausecancer,birthdefects,andotherreproductiveharm.
© KPI-JCI 2014
Record your Series 40 conveyor serial and order number in the space provided below.
You will find the serial number plate located on the support frame.
Please include these numbers when requesting service or ordering replacement parts.
JOB ORDER
MODEL S/N
MANUFACTURED BY KOLBERG-PIONEER, INC. YANKTON, SD, U.S.A.
Serial Number Plate

OPERATION &
MAINTENANCE
MANUAL
Series 40
Transflite and
Stationary Conveyor
Models Covered:
Stationary
Model 41 - 8” Channel Frame
Model 42 - 24” Lattice Frame
Model 43 - 30” Lattice Frame
Model 44 - 36” Lattice Frame
Model 45 - 42” Lattice Frame
Model 46 - Channel and Lattice Frame
Transflite
43-2460T 43-3660T
44-2480T 44-3680T
44-24100T 44-36100T
43-3060T
44-3080T
44-30100T

Printed in the USA
Allrightsreserved. Nopartofthismanualmaybereproduced
or transmitted in any form or by any means, electronic or
mechanical, including photocopying, recording or by any
informationstorageorretrievalsystem,withoutpermission
from KPI-JCI.
Thismanualcontainsoperatinginstructions,lubrication,and
maintenance information. Application of this information
shouldmaximizetheperformanceandlifeofyourequipment
and minimize down time.
Safe and efficient operation requires that anyone who
will be operating or maintaining this equipment read
and understand the safety, operation, maintenance, and
troubleshooting information contained in the operator’s
manual.
Continuing improvement and advancement of KPI-JCI
products may cause changes to your equipment which
may not be reflected in this publication.
KPI-JCI reserves the right to make changes or add
improvementsto its productsat any time,without incurring
any obligation to make such changes on previously
manufactured equipment.
Although care has been taken to assure the accuracy of
this publication, KPI-JCI does not assume any liability for
loss, damage or injury caused by errors or omissions.

Contents
Introductory Pages About This Manual 7
Serial Number Plates 8
Buying Replacement Parts 9
Maintenance Techniques and Tools 10
Lubricants and Fluids 11
Storage 12
Introduction to the Series 40
Covneyor Chapter 1 13
Safety Chapter 2 19
Unloading Conveyor Chapter 3 30
Site Selection and Preparation Chapter 4 32
Conveyor Setup Chapter 5
Frame Sections/Belt Idlers 33
Receiving Hopper/Drives/Electrical 34
Conveyor Support Assembly 35
Conveyor Belt Chapter 6
Installation/Belt Tensioning 36
Belt Splicing 37
Belt Fastener Installation 38
Belt Training/Belt Cleaning 40
Belt Loading 41
Preoperation/Operation
Checklist Chapter 7 42
Maintenance Chapter 8
10 hours 44
50 hours 45
200 hours 47
Lubrication Chapter 9
50 hours 51
200/2500 hours 53
As needed 54
Troubleshooting Chapter 10 55
Disc Wheel Installation Appendix A
Prevailing Torque Locknut Appendix B
Belt Tension Instructions Appendix C
Warranty Registration and Preoperation Check

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Purpose
The purpose of this manual is
to help you get the best value
from your equipment. It can
do so by helping you decide
whatworkmustbedone,even
ifyoudecidetohaveitdoneby
adealerservicedepartmentor
a repair shop. It also provides
information and procedures
for routine maintenance and
servicing.
Using the Manual
The manual is divided into
chapters which are further
dividedintonumberedsections,
headed in bold type between
horizontal lines. Each section
consists of consecutively
numbered paragraphs.
About This Manual
Procedures, once described
in the text, are not normally
repeated. Whenitisnecessary
to refer to another chapter,
the reference will be given as
chapter and section number.
Crossreferencesgivenwithout
the word “chapter” apply to
sections and/or paragraphs in
thesamechapter,“seesection
8”means inthe samechapter.
Even though this manual
has been prepared with
extreme care, KPI-JCI cannot
acceptresponsibilityfor errors
in, or omissions from the
information given.
Special Notations
Withinthismanualprocedures
orsituationsthatrequirespecial
attentionareindicatedwiththe
words, DANGER,WARNING,
CAUTION and IMPORTANT.
DANGER, WARNING and
CAUTIONareusedtoindicate
proceduresorsituations where
personal safety is involved.
IMPORTANT is used to
indicate special procedures
or situations which, if not
observed, could result in
damage to the equipment
or affect the operation of the
machine.

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Serial Number Plate
Modifications are a continuing
processinthemanufactureofthis
equipment. Since replacement
parts, manuals, and lists are
compiled specifically for each
unit, the serial numbers are
essentialtocorrectlyidentifythe
component required.
Theserialnumberplatewillshow
the serial number, job order
number and model number.
Series 40 Serial Number
The serial number for the
Series40conveyorisstamped
on a plate which is located on
the conveyor frame.
Theserialnumber(S/N)isthe
numberthatshouldbereferred
to when ordering parts or
requesting service.
Serial number plate located near the tail end of the conveyor
Serial number plate
Tail end

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Authorized Dealer Parts
Department
An authorized dealer parts
department is the best source
for parts, particularly parts
which are unique to this
equipment. Ifyoudonotknow
who the authorized dealer
is in your area contact KPI-
JCI. Dealerships are located
throughout the United States
and some parts of the world.
Buying Replacement Parts
Purchased Components
Replacement parts for
components purchased by
KPI-JCIsuchasgearreducers,
electric motors, and engines
are available through your
authorized dealer. However,
items like engine parts are
typically not stocked by the
dealer or KPI-JCI.
Serial Number
Since replacement parts
manualsandlistsarecompiled
specifically for each unit, the
serialnumbersareessentialto
correctlyidentifythecomponent
required.

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Tools
Althougha minimal number of
toolsareneededforoperation
and maintenance, a good
selection of basic tools is
required.
Waste Oil and Fluids
Waste oil and fluids drained
from the engine and hydraulic
system during normal
maintenance and repair can
present a disposal problem.
To avoid pouring them on the
ground or into the sewage
system, pour the used fluids
intolargecontainers,sealthem
andtakethemtoanauthorized
disposal or recycling center.
Maintenance Techniques and Tools
Fasteners
Typically, standard SAE
fastenersareused. Fasteners
are nuts, bolts, studs and
screws used to hold two or
more parts together.
All threaded fasteners should
be clean and straight, with
undamaged threads and
undamaged corners on the
hex heads.
It is a good habit to replace
all damaged fasteners when
performingmaintenance-never
reuse a damaged fastener.
Special locknuts with nylon
insertscanonlybeusedonce.
If they are removed, they lose
their locking ability and must
be replaced.
Rusted nuts and bolts should
be treated with a penetrating
fluid to ease removal and
prevent breakage. Badly
rusted fasteners may have to
bechiseled,sawed,ortorched
off.
Flatwashersandlockwashers,
when removed from an
assembly, should always be
replaced exactly as removed.
Whenreplacingnutsandbolts,
be sure to use the correct
grade. Never use a different
grade of bolt than the original
equipment.

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Lubricants and Fluids
Gear Reducers.
ISO 220 Gear Oil
Bearings, Pivot Points and
General Lubricant
EP-2Lithium Based Grease
The lubricants shown to the
rightare“factoryfill”lubricants.
Other lubricants may be
used, provided they meet
the lubrication requirements
specified.
Bearings
Bearings are lubricated with a
high temp EP-2 lithium based
grease containing a tackiness
agent. Lube color is red.
Gear Reducers
Gear reducers are filled with
ahigh grade petroleum based
rustandoxidationinhibitedgear
oil. Forambienttemperatures
15 to 60 degrees Fahrenheit,
ISO viscosity grade 220 is
used. Fortemperatures50-125
degreesFahrenheit MobilDTE
Oil Extra Heavy ISO viscosity
grade 150 can be used.
For temperatures above 125
degreesFahrenheit,useMobil
SHC634andfortemperatures
20 to -22 degrees Fahrenheit
use Mobil SHC 627.